Low leak poppet solenoid

ABSTRACT

A dual poppet low leak variable bleed solenoid valve, including a solenoid portion with an adjustable end cap disposed through the solenoid. Exhaust ports are disposed about the end cap. A hydraulic portion has a valve housing that is connectable to the solenoid portion. The hydraulic portion has a control volume formed within, and a supply port is connected through the valve housing. A valve shaft is slidably disposed through the solenoid portion and extends longitudinally into the hydraulic portion. A first end of the valve shaft terminates in the solenoid portion forming a primary valve, and a second end of the valve shaft terminates in the hydraulic portion forming a secondary valve. The valve shaft further has a hollow channel disposed through the valve shaft to allow the passage of a fluid medium between the first end and second end of the valve shaft.

FIELD OF THE INVENTION

The present invention relates to a solenoid operated bleed-style hydraulic control valve that minimizes leakage through the exhaust port when the solenoid is at minimum and maximum pressure.

BACKGROUND OF THE INVENTION

Prior art solenoid valves are often used to control the flow of hydraulic fluid in automotive vehicle transmission systems. A traditional variable bleed solenoid valve regulates pressure by reducing pressure in a control volume through a variable leak path (exhaust) to a pressure sump. The amount of leakage is inversely proportional to the pressure in the control portion of the valve. This leakage is controlled by a variable orifice, which typically takes the form of a sealing member (flat, conical, ball, or otherwise) that is moved in relation to a fixed annular sealing surface that surrounds a fixed orifice. When the sealing member is in contact with the sealing surface, the leakage approaches zero, and the pressure in the control volume is at its peak value. When the sealing member is moved away from the sealing surface, the leakage increases, and the pressure in the control volume decreases at a rate that is a function of the swept area of the shortest distance between sealing member and seat. The leakage can be significant when multiplied by the number of solenoid devices located within the transmission. Minimizing the leakage of each of the individual solenoid components is desirable in order to minimize the capacity requirement of the hydraulic pump that generates the system pressure and to improve the efficiency of the transmission. A low leak variable bleed solenoid by design minimizes this leakage. Minimal leakage to sump is achieved by integrating a supply shut off (secondary) valve in series with the exhaust bleed (primary) valve. These two valves are actuated simultaneously. When the exhaust bleed (primary) valve is fully open to achieve minimum control volume pressure, the supply shut off (secondary) valve is fully closed to prevent fluid leakage to sump through the control volume. As the exhaust bleed (primary) valve is closed to increase pressure in the control volume, the supply shut off (secondary) valve is opened to allow fluid to enter into the control volume. At maximum pressure in the control volume, the exhaust bleed (primary) valve is fully closed and the supply shut off (secondary) valve is fully open.

A disadvantage of known low leak variable bleed solenoid valves is that the addition of a supply shut off valve in close proximity to the exhaust bleed valve complicates the construction of the solenoid valve. Additional components that re-direct flow often have complex geometries that are difficult and expensive to manufacture. Another disadvantage is that many of the known low leak variable bleed solenoid valves are more sensitive to fluctuations in supply pressure and temperature as they have hydraulic areas acted upon by supply pressure that are not balanced. The invention described herein differs from the prior art by utilizing simpler valve and flow geometry, which also has the advantage of minimizing supply pressure feedback area.

SUMMARY OF THE INVENTION

The present invention is directed to a new and improved low leak poppet solenoid valve for use in an automotive transmission system. The valve includes a solenoid portion (e.g. magnet portion) having a housing encasing a bobbin with a coil wound thereon. An adjustable end cap is disposed, through the housing and has exhaust port(s) disposed about the end cap. A hydraulic portion has a valve housing that is connectable to the solenoid portion. The hydraulic portion has a control volume formed within, and a supply port is connected through the valve housing. A valve shaft assembly comprised of the valve shaft and an annular armature attached about it are slidably disposed through the solenoid portion so the bobbin is annularly positioned about the armature. The hydraulic portion extends through the solenoid portion by way of a the valve shaft to complete the hydraulic portion. The valve shaft has a first end that terminates in the adjacent solenoid portion and has a poppet formed about the first end. A second end of the valve shaft is positioned adjacent the hydraulic portion and has a second poppet formed about the second end. The valve shaft further has a hollow channel disposed through the valve shaft to allow the passage of a fluid medium between the first end and second end of the valve shaft.

A primary valve seat is formed as part of the end cap and is contained within the solenoid portion. The primary valve is the main controlling valve during most of the pressure range. The primary valve seat is configured to be positioned adjacent the primary poppet on the valve shaft. A secondary valve seat is contained within the hydraulic portion and is positioned adjacent the secondary poppet of the valve shaft. The secondary valve seat is positioned between the control volume and the supply port of the hydraulic portion. Furthermore, the secondary valve seat has an aperture extending therethrough to allow interaction between the supply port and control volume. The secondary poppet provides control of the secondary control valve in the low pressure range.

A pole piece is annularly disposed in the solenoid portion adjacent the bobbin. The pole piece has a reduced diameter inner flange. An armature is attached to the valve shaft and is configured to align with and slidably circumscribe the reduced inner diameter flange of the pole piece. The armature is circumscribed by the bobbin and coil so that the valve shaft may slide longitudinally in response to the energization of the solenoid portion. In one embodiment a spring element is configured about the valve shaft and extends between the armature and the upper bearing so that when the solenoid is de-energized the spring element will cause the valve shaft to slide in a direction that will cause the secondary poppet to contact the secondary valve seat.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 depicts a cross-sectional plan view of the dual poppet low leak valve configuration;

FIG. 1 a depicts a broken away cross-sectional plan view of a first alternate embodiment of the secondary valve shown in FIG. 1;

FIG. 1 b is a broken away cross-sectional plan view of a second alternate embodiment of the secondary valve shown in FIG. 1;

FIG. 1 c is a broken away cross-sectional plan view of a third alternate embodiment of the secondary valve shown in FIG. 1;

FIG. 2 depicts a cross-sectional plan view of a second embodiment of the dual poppet low leak valve configuration;

FIG. 3 is a cross-sectional plan view of a third embodiment of the invention having a tapered valve shaft; and

FIG. 4 is a cross-sectional plan view of another embodiment of the invention having a diaphragm for sealing the hydraulic portion from the motorized portion.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

FIG. 1 depicts a longitudinal cross-sectional plan view of a dual-poppet low leak variable bleed solenoid valve 10. The valve 10 has a solenoid portion 24 b which includes a housing 14 that encases a bobbin 16 having a coil 18 wound upon the bobbin 16. When the coil 18 is energized there is a magnetic field generated in the solenoid portion 12. The solenoid portion 12 also has an end cap 20 that has exhaust ports 22 disposed about the end cap 20.

The valve 10 also has a hydraulic portion 24 a that has a valve housing 26 that is connectable to the solenoid portion 24 b. More specifically, a flux tube 28 portion of the valve housing 26 slides into the solenoid portion 24 b adjacent the bobbin 16. The hydraulic portion 24 a also includes a control volume 30 that is located at an end of the valve housing 26 opposite the solenoid portion 24 b. A supply port 32 is connected through the valve housing 26 at a position located above the control volume 30. In the current embodiment, the valve housing 26 is mated to an external bore and an O-ring seal 33 separates the supply pressure region that is external to the valve housing 26 from the control volume 30. A second O-ring seal 35 separates the supply pressure region that is external to the valve housing 26 from the ambient or sump pressure region. It will be readily appreciated that the other fittings could be used for securing the valve body in the manifold. Alternatively, the valve body can be made as part of the manifold.

A valve shaft 34 is slidably disposed through the solenoid portion 24 b and extends longitudinally into the hydraulic portion 24 a. The valve shaft 34 has a hollow channel 36 extending through the longitudinal axis of the valve shaft 34. The hollow channel 36 allows the passage of fluid medium from the hydraulic portion 24 a to the solenoid portion 24 b. Additionally, the hollow channel 36 may serve the purpose of damping the movement of the valve shaft 34, thus improving the stability of the solenoid valve 10.

The hollow channel 36 has a first end that terminates at a primary valve 38 located within the solenoid portion 24 b. The primary valve 38 is formed of a primary poppet 40 that is formed about the end of the valve shaft 34, and a primary valve seat 42 that is formed in the end cap 20. Together the primary poppet 40 and the primary valve seat 42 form the primary valve 38 which is opened and closed by the sliding of the valve shaft 34 along its longitudinal axis.

The hollow channel 36 has a second end that terminates at a secondary valve 44 located in the hydraulic portion 24 a. The secondary valve 44 is formed of a secondary poppet 46 which is the end of the valve shaft 34. The secondary poppet 46 is configured to slidably seat against a secondary valve seat 48 which has an aperture 50 that extends through the secondary valve seat 48 to the control volume 30. Together the secondary poppet 46 and the secondary valve seat 48 form the secondary valve 44 which is controlled by the movement of the valve shaft 34.

FIGS. 1 a, 1 b and 1 c depict alternate embodiments of the secondary valve 44. In FIG. 1 a the secondary valve 44 does not include the secondary poppet 46. Instead the end of the valve shaft 34 will contact and abut against the secondary valve seat 48 to close the secondary the valve 44.

FIG. 1 b depicts another alternate embodiment of the secondary valve 44 wherein the secondary valve seat 48 has a raised nozzle 47. The valve shaft 34 is aligned with the raised nozzle 47 so that the end of the valve shaft 34 slides over and circumscribes the raised nozzle 47. This configuration is useful in applications that require a tighter seal to prevent unwanted leaking of the secondary valve 44.

FIG. 1 c depicts an alternate embodiment of the secondary valve 44, wherein the secondary valve seat 48 has a tapered surface 49. The end of the valve shaft 34 has a ring 51 that circumscribes and forms a flanged overhang of the end of the valve shaft 34. The ring 51 contacts the tapered surface 49 of the secondary valve seat 48. The ring 51 functions to provide a tighter seal to prevent unwanted leakage of the secondary valve 44.

It is also within the scope of this invention to incorporate the alternate embodiments shown in FIGS. 1 a, 1 b and 1 c with the primary valve 38 located in the solenoid portion 24 b. The primary valve 38 can be configured so that there is no primary poppet 40 and the end of the valve shaft 34 will close the primary valve 38 by abutting against the primary valve seat 42. This would be analogous to the embodiment shown in FIG. 1 a.

It is also within the scope of this invention to configure the primary valve 38 so that the primary valve seat 42 has a raised nozzle and the end of the valve shaft 34 configures to slide over and circumscribe the raised nozzle in a manner similar to the alternate embodiment of the secondary valve 44 shown in FIG. 1 b.

Lastly it is within the scope of this invention to configure the primary valve 38 so that the primary valve seat 42 has a tapered surface with the end of the valve shaft 34 having a ring that circumscribes and forms a flanged overhand on the end of the valve shaft 34. The ring will contact the tapered surface of the primary valve seat 42 to form a tight seal. This embodiment of the primary valve 38 will operate in a manner similar to the ring 51 in tapered surface 49 shown in FIG. 1 c.

In operation the dual poppet low leak valve 10 functions in response to the energization of the solenoid portion 12. When the coil 18 is energized, the valve shaft 34 will slide in a first direction along its longitudinal axis. In order to facilitate the movement of the valve shaft 34, an armature 52 is annularly disposed about and affixed, such as being press fit, or could also be glued, soldered or welded to the valve shaft 34. The armature 52 is affected by the magnetic flux generated as a result of the energization of the coil 18. This causes a linear movement of the valve shaft 34 that is proportional to the degree of current flowing through the coil 18 in the solenoid portion 12. When the solenoid portion 12 is energized, the valve shaft 34 will slide in a first direction toward the end cap 20 so that the primary poppet 40 will seat against the primary valve seat 42, thus closing off the primary valve 38. Simultaneously, the secondary valve 44 will be opened as the movement of the valve shaft 34 will cause the secondary poppet 46 to move away from the secondary valve seat 48.

In the present embodiment of the invention, when the coil 18 of the solenoid portion 12 is de-energized a spring 60 will cause the armature 52 to slide in a second direction opposite the movement of the armature 52 when it is energized. The spring 60 in the present embodiment of the invention is disposed between the armature 52 and the upper bearing 64. When the solenoid portion 12 is de-energized, the spring 60 will exert force against the armature 52 to cause the valve shaft 34 to move in the opposite direction so that the secondary valve 44 is closed as the secondary poppet 46 contacts the secondary valve seat 48. Simultaneously, the primary valve 38 will move to the fully opened position as the primary poppet 40 moves away from the primary valve seat 42. In order to ease the movement of the valve shaft 34, a lower bearing 62 is positioned between the wall of the valve housing 26 and the valve shaft 34, and an upper bearing 64 is positioned between the valve shaft 34 and the pole piece 54, thus allowing the valve shaft 34 to more freely slide along its longitudinal axis.

In order to achieve the desired proportional magnetic flux, a pole piece 54 is disposed in the solenoid portion 12 located adjacent to a portion of the bobbin 16. In this particular embodiment, the pole piece 54 has a reduced inner diameter flange 56 which is configured to overlap the armature 52 when the solenoid portion 12 is energized. The overlapping flange 56 causes the desired proportional magnetic flux to be achieved because the geometry of the flanges 56, affects the distribution of the magnetic field generated by the energized coil 18.

FIG. 2 depicts a cross-sectional plan view of an alternate embodiment of the dual poppet low leak valve configuration. The alternate embodiment shown in FIG. 2 differs from the embodiment shown in FIG. 1 with respect to the positioning of the pole piece, flux tube, spring and armature. FIG. 2 shows a pole piece 54′ that is part of the hydraulic portion 24. The pole piece 54′ has an increased diameter inner portion 56′ that is configured to overlap for shaping magnetic characteristics the armature 52. A spring 60′ is disposed between the armature 52 and the lower bearing 62. In this particular embodiment of the invention, when the solenoid portion 12 is energized the armature 52 will move in a first direction to close the secondary valve 44 by causing the secondary poppet 46 to come into contact with the secondary valve seat 48. Simultaneously, the primary valve 38 will be opened as the primary poppet 40 moves away from the primary valve seat 42. When the solenoid portion 12 is de-energized, the spring 60′ will exert force against the armature 52 and cause the valve shaft 34 to slide in a second direction so that the primary valve 38 becomes closed as the primary poppet 40 comes into contact with the primary valve seat 42. Simultaneously, the secondary valve 44 will be opened as the secondary poppet 46 moves away from the secondary valve seat 48. This is what is referred to as a normally closed valve since the primary valve 38 is in the closed position when the solenoid portion 24 b is de-energized. The operation of the dual poppet low leak valve 10′ in this particular embodiment is similar to the embodiment depicted in FIG. 1 with the exception that when the solenoid portion 12 is energized, the primary valve 38 will be opened and the secondary valve 44 will be closed, whereas, in FIG. 1 when the valve 10 becomes energized the primary valve 38 will be closed, while the secondary valve 44 will be opened.

FIG. 3 depicts an alternate embodiment of FIG. 2. This particular embodiment has a valve shaft 34 that has a large diameter portion 66 and a smaller diameter portion 68. The spring 60 will extend between the lower bearing 62 and a shoulder 70. In this embodiment the spring 60 does not extend into the solenoid portion 24 b, and it acts directly upon the valve shaft 34 instead of the armature 52. Like the valve depicted in FIG. 2, the valve in this embodiment is also configured so the primary valve 38 is in the closed position when the solenoid portion 24 b is de-energized (i.e., a normally closed valve).

FIG. 4 depicts an alternate embodiment of FIG. 1. This particular embodiment has a valve shaft 34 that has a large diameter portion 66 and a small diameter portion 68. The spring 60 will extend between the upper bearing 64 and armature 52. Additionally, this embodiment has a diaphragm 72 which functions to seal the solenoid portion 24 b from the hydraulic valve portion 24 a. Like the valve depicted in FIG. 1, the valve depicted in this particular embodiment is what is referred to as a normally open valve since the primary valve 38 is in the open position when the solenoid portion 24 b is de-energized.

The method of operating the valve described permits a same pressure regulation function while reducing the amount of hydraulic fluid exhaust leakage to the sump as compared to a conventional variable bleed solenoid. This is accomplished by an integrated supply shut off (secondary) valve 44 that is actuated in conjunction with the exhaust bleed (primary) valve 38. At low pressure, the secondary valve 44 blocks supply pressure from the supply port 32 from entering the control volume 30. As the solenoid 12 is actuated, the secondary valve 44 is opened as the secondary poppet 46 is moved away from the secondary valve seat 48, allowing supply pressure into the control volume 30 and the primary valve 38 moves toward the closed position as the primary poppet 40 moves toward the primary valve seat 42 thereby, incrementally reducing exhaust leakage and increasing pressure in the control volume 30 at the stroke limit of the solenoid 12. As the primary poppet 40 approaches the primary valve seat 42 surface, the secondary valve 44 is opened to its fullest extent. At this point the pressure in the control volume 30 is at its peak, and the exhaust leakage is minimized.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. 

1. A solenoid valve comprising: a solenoid portion having a housing encasing a bobbin with a coil wound thereon and an exhaust passage disposed through an end of said housing; a hydraulic portion having a valve housing connectable to said solenoid portion and a control volume connected to said hydraulic portion; a supply port connected through said valve housing of said hydraulic portion; a valve shaft including an armature slidably disposed through said solenoid portion and said bobbin being annularly positioned about said armature, said valve shaft extending from said solenoid portion into said hydraulic portion, said valve shaft including a first end terminating positioned adjacent in said solenoid portion and a second end positioned adjacent said hydraulic portion; a first valve located at the first end of said valve shaft; and a second valve located at the second end of said valve shaft, wherein when said valve shaft is moved in a first direction the secondary valve moves toward an open position and said primary valve moves toward a closed position and when moved in a second direction the secondary valve moves toward a closed position and said primary valve moves toward an open position.
 2. The solenoid valve of claim 1 further comprising a hollow channel disposed through said valve shaft to allow the fluid communication between said secondary valve and said primary valve.
 3. The solenoid valve of claim 2 wherein said hollow channel may provide viscous dampening of said valve shaft to improve the stability of the solenoid valve.
 4. The solenoid valve of claim 1 further comprising an adjustable end cap disposed through said housing of said solenoid wherein said exhaust ports are disposed about said end cap.
 5. The solenoid valve of claim 4 wherein said primary valve is formed of a primary poppet formed about said first end of said valve shaft and a primary valve seat formed in said end cap adjacent said primary poppet; said secondary valve being comprised of a secondary poppet formed about said second end of said valve shaft and a secondary valve seat contained within said hydraulic portion and having an aperture extending through said secondary valve seat, wherein said secondary valve seat is positioned between said control volume and said supply port.
 6. The dual poppet low leak variable bleed solenoid valve of claim 1 further comprising: a pole piece annularly disposed in said solenoid portion adjacent said bobbin, wherein said pole piece has a reduced inner diameter flange and is configured to align with and slidably circumscribe said armature, wherein said armature is circumscribed by said bobbin and coil so that said armature and said valve shaft slide about the longitudinal axis of said valve shaft in response to the energization of said solenoid portion.
 7. The solenoid valve of claim 6 further comprising: one or more lower bearings disposed between said valve shaft and said housing, wherein said one or more lower bearings function to facilitate the sliding of said valve shaft; and a spring configured about said valve shaft and extending between said armature and said one or more upper bearings, wherein said solenoid portion is de-energized said spring applies force to said armature to slide said valve shaft so said primary valve is in the open position and said secondary valve is in the closed position.
 8. A solenoid valve comprising: a solenoid portion having a housing encasing a coil assembly and an adjustable end cap disposed though said housing said end cap including surfaces forming exhaust ports disposed about said end cap; a hydraulic portion having a valve housing connectable to said solenoid portion and a control volume formed within said hydraulic portion; a supply port connected through said valve housing of said hydraulic portion; a valve shaft slidably disposed through said solenoid portion so said bobbin is annularly positioned about said valve shaft and extending from said solenoid portion into said hydraulic portion, wherein a first end of said valve shaft terminates in said solenoid portion and has a primary poppet formed about said first end, and a second end of said valve shaft terminates in said hydraulic portion and has a secondary poppet formed about said second end; a hollow channel disposed though said valve shaft to allow the passage of a medium between said first end and said second end of said valve shaft; a primary poppet seat contained within said solenoid portion, said primary valve seat being formed in said end cap adjacent the primary poppet of said valve shaft; a secondary valve seat contained within said hydraulic portion and having an aperture extending through the seat, wherein said secondary valve seat is positioned between said control volume and said supply port; a pole piece is annularly disposed in said solenoid portion adjacent said bobbin, wherein said pole piece has a reduced inner diameter flange; and an armature attached to said valve shaft, said armature configured to align with and slidably inscribe said reduced inner diameter flange of said pole piece, wherein said armature circumscribed by said bobbin and coil and said armature and said valve shaft is configured to slide longitudinally in response to the energization of said solenoid portion.
 9. The solenoid valve of claim 8 further comprising a spring configured about said valve shaft, wherein said spring is biased to move said secondary poppet in a direction to contact said secondary valve seat placing said dual poppet low leak solenoid valve in a normally closed or normally high pressure position.
 10. The solenoid valve of claim 8 further comprising a spring configured about said valve shaft, wherein said spring is biased to move said primary poppet in a direction to contact said primary valve seat, placing said valve in a normally opened or normally low pressure position. 11-16. (canceled)
 17. A valve comprising: a motorized portion having a housing; a hydraulic portion having a housing connectable to said housing of said motorized portion; a valve shaft disposed though said hydraulic portion and extending into said motorized portion and a hollow channel extending through said valve shaft, wherein said valve shaft and said hollow channel have a first end terminating in said motorized portion and a second end terminating in said hydraulic portion; a first valve located at said first end of said hollow channel, wherein when said valve shaft is moved in a first direction the first valve moves toward a closed position and when said valve shaft is moved in a second direction the first valve moves toward an open position.
 18. The valve of claim 17 further comprising a second valve located at a second end of said valve shaft, wherein when said valve shaft is moved in said first direction said second valve moves toward an open position and when said valve shaft is moved in a second direction said second valve moves toward a closed position.
 19. The valve of claim 18 wherein said first valve is formed of a primary first poppet formed about said first end of said valve shaft and a primary valve seat formed in an end cap adjacent said primary first poppet; and said second valve having a second poppet formed about said second end of said valve shaft and a second valve seat contained within said hydraulic portion and having an aperture extending through said second valve seat.
 20. The valve of claim 18 further comprising a spring configured about said valve shaft, wherein said spring is biased to move said valve shaft in said second direction. 21-39. (canceled) 